The document discusses criteria for maximizing output and use of alternative fuels and raw materials (AFR) at cement plants while meeting occupational health and safety (OH&S) requirements. It outlines how to understand the impact of AFR on plant operations and emissions in order to minimize output losses through proper pre-processing, handling, and process optimization aided by modeling software. The document also stresses the importance of understanding potential OH&S risks associated with waste handling and implementing controls at all stages of the waste management process.
Tailor-made catalyst solutions to meet the demands for lower SO2 emissions - ...COBRAS
This presentation describes the Topsoe WSA technology and why it was chosen by the Buenaventura group for their plant at Procesadora Industrial Rio Seco S.A. plant located near Huaral which is about 100 km from Lima in Peru. At this site, magnesium sulfates are produced and a waste stream containing among others H2S has to be cleaned before it is sent to the atmosphere. This gas stream is treated in the WSA plant, and at the same time solid sulfur is burned, whereas 98.0 wt% sulfuric acid is produced by both feed materials for consumption at the site at a capacity of 60 MTPD.
The installation of the plant at site, the precommissioning and commissioning of the WSA plant as well as the first experience of operation also are described
Oils and their relationship to refrigeration systems -RETA conference 2015Manuel Muñoz Alonso
These are the slides of the technical paper presented in the RETA Conference 2015 (www.reta.com), used during my lecture. A good review of the latest lubricant technology available for natural refrigerants.
Estas son las transparencias utilizadas en el Congreso anual de RETA (www.reta.com) durante mi presentación. Un buen resumen de las úlitimas tenologías de lubricantes disponibles para los refrigerantes naturales.
Acetylene Hydrogenation - Consultancy
Ethylene Plant Flowsheets
Placement of Acetylene Hydrogenation Reactor
Cracker Feedstock / Product Variability
Acetylene Reactor Feeds
Reasons for Acetylene Removal
Reacting Components and Conditions
Reactor Operation and Reacting Components
Reactor Design
Selectivity vs. Temperature and Ethane Formation
Effect of CO
Poisons
Green Oil
Turndown
H/D Ratio and Pressure Drop
Thermocouple Placement
Start-up
Problems During Start-up
Shut Down
Regeneration
Catalyst Experience, Problems and Other Information
Front End / Tail End Comparison
Nu energy - cokemaking technology for current challengesJorge Madias
This presentation deals with a technology for formed coke production. Milestones in the development of this technology are summarized. Then, the equipment and the process are described. The environmental impact is briefly addressed. The products obtained along the processes, including char, gas, liquids and coke are characterized, and possible applications are mentioned. As an example, an economical evaluation of a given project is detailed. Finally, a coke cost exercise is carried out.
DEBOTTLENECKING METALLURGICAL AND SULPHUR-BURNING SULPHURIC ACID PLANTS: CAPA...COBRAS
Guy Cooper presents general strategies for acid plants, as reduction of pressure drop by modifying or replacing plant equipment, increase of SO2 gas concentration, blower upgrades, steam system debottlenecking, and strategies to reduce emissions. Aspects specific to metallurgical acid plants such as: improvements to gas-cleaning, increasing blower suction pressure, control of air dilution to acid plant, and handling the variation of process conditions are discussed. Aspects specific to sulphur-burning plants such as sulphur handling and sulphur burning are also discussed.
Minimising emissions, maximising alternative fuelsA TEC Group
Dr. Stefan Kern, A TEC Production and Services GmbH, details the conversion of the kiln at Lafarge Retznei and shows how an optimised calciner design allowed for 100% alternative fuel usage.
"Minimising emissions, maximising alternative fuels". Article published on World Cement Magazine, edition June 2022.
Debottlenecking Claus Sulfur Recovery Units: An Investigation of the applicat...Gerard B. Hawkins
Debottlenecking Claus Sulfur Recovery Units: An Investigation of the application of Zinc Titanates
1 Executive Summary
2 Claus Process
2.1 Partial Combustion Claus
2.2 Split Flow Claus
2.3 Sulfur Recycle Claus
3 Zinc Titanates
4 Application of Zinc Titanate to Debottleneck Partial Combustion Claus by 10%
4.1 Process
4.2 ASPEN Modeling Results
4.3 Cost of Zinc Titanate Bed Installation
4.3.1 Basis of Costing
4.3.2 Zinc Titanate Beds
4.3.3 Regen Cooler
4.3.4 Blowers
4.3.5 Results
4.4 Alternative Debottlenecking Technology for Partial Combustion Claus
4.5 Cost of 10% Debottlenecking Using COPE Process
5 Debottlenecking Claus Split Flow System by 10% with Zinc Titanates
6 Debottlenecking Claus Sulfur Recycle System With Zinc Titanate
7 Effect of Zinc Titanate Debottlenecking on Existing Tail; Gas Treatment Systems
7.1 Selectox
7.2 SuperClaus99
7.3 Superclaus 99.5
7.4 SCOT Process
7.5 Zinc Titanate as a Claus Tail Gas Treatment
7.6 H2S Removal Efficiency With Zinc Titanate
8 Effects on COS and CS2 Formation
9 Questions for further Investigation
FIGURES
Figure 1 Claus Unit and TGCU
Figure 2 Claus Process
Figure 3 Typical Claus Sulfur Recovery Unit
Figure 4 Two-Stage Claus SRU
Figure 5 The Super Claus Process
Figure 6 SCOT
Figure 7 SCOT/BSR-MDEA (or clone) TGCU
REFERENCES: PATENTS
US4333855_PROMOTED_ZINC_TITANATE_CATALYTIC_AGENT
US4394297_ZINC_TITANATE_CATALYST
US6338794B1_DESULFURIZATION_ZINC_TITANATE_SORBENTS
Tailor-made catalyst solutions to meet the demands for lower SO2 emissions - ...COBRAS
This presentation describes the Topsoe WSA technology and why it was chosen by the Buenaventura group for their plant at Procesadora Industrial Rio Seco S.A. plant located near Huaral which is about 100 km from Lima in Peru. At this site, magnesium sulfates are produced and a waste stream containing among others H2S has to be cleaned before it is sent to the atmosphere. This gas stream is treated in the WSA plant, and at the same time solid sulfur is burned, whereas 98.0 wt% sulfuric acid is produced by both feed materials for consumption at the site at a capacity of 60 MTPD.
The installation of the plant at site, the precommissioning and commissioning of the WSA plant as well as the first experience of operation also are described
Oils and their relationship to refrigeration systems -RETA conference 2015Manuel Muñoz Alonso
These are the slides of the technical paper presented in the RETA Conference 2015 (www.reta.com), used during my lecture. A good review of the latest lubricant technology available for natural refrigerants.
Estas son las transparencias utilizadas en el Congreso anual de RETA (www.reta.com) durante mi presentación. Un buen resumen de las úlitimas tenologías de lubricantes disponibles para los refrigerantes naturales.
Acetylene Hydrogenation - Consultancy
Ethylene Plant Flowsheets
Placement of Acetylene Hydrogenation Reactor
Cracker Feedstock / Product Variability
Acetylene Reactor Feeds
Reasons for Acetylene Removal
Reacting Components and Conditions
Reactor Operation and Reacting Components
Reactor Design
Selectivity vs. Temperature and Ethane Formation
Effect of CO
Poisons
Green Oil
Turndown
H/D Ratio and Pressure Drop
Thermocouple Placement
Start-up
Problems During Start-up
Shut Down
Regeneration
Catalyst Experience, Problems and Other Information
Front End / Tail End Comparison
Nu energy - cokemaking technology for current challengesJorge Madias
This presentation deals with a technology for formed coke production. Milestones in the development of this technology are summarized. Then, the equipment and the process are described. The environmental impact is briefly addressed. The products obtained along the processes, including char, gas, liquids and coke are characterized, and possible applications are mentioned. As an example, an economical evaluation of a given project is detailed. Finally, a coke cost exercise is carried out.
DEBOTTLENECKING METALLURGICAL AND SULPHUR-BURNING SULPHURIC ACID PLANTS: CAPA...COBRAS
Guy Cooper presents general strategies for acid plants, as reduction of pressure drop by modifying or replacing plant equipment, increase of SO2 gas concentration, blower upgrades, steam system debottlenecking, and strategies to reduce emissions. Aspects specific to metallurgical acid plants such as: improvements to gas-cleaning, increasing blower suction pressure, control of air dilution to acid plant, and handling the variation of process conditions are discussed. Aspects specific to sulphur-burning plants such as sulphur handling and sulphur burning are also discussed.
Minimising emissions, maximising alternative fuelsA TEC Group
Dr. Stefan Kern, A TEC Production and Services GmbH, details the conversion of the kiln at Lafarge Retznei and shows how an optimised calciner design allowed for 100% alternative fuel usage.
"Minimising emissions, maximising alternative fuels". Article published on World Cement Magazine, edition June 2022.
Debottlenecking Claus Sulfur Recovery Units: An Investigation of the applicat...Gerard B. Hawkins
Debottlenecking Claus Sulfur Recovery Units: An Investigation of the application of Zinc Titanates
1 Executive Summary
2 Claus Process
2.1 Partial Combustion Claus
2.2 Split Flow Claus
2.3 Sulfur Recycle Claus
3 Zinc Titanates
4 Application of Zinc Titanate to Debottleneck Partial Combustion Claus by 10%
4.1 Process
4.2 ASPEN Modeling Results
4.3 Cost of Zinc Titanate Bed Installation
4.3.1 Basis of Costing
4.3.2 Zinc Titanate Beds
4.3.3 Regen Cooler
4.3.4 Blowers
4.3.5 Results
4.4 Alternative Debottlenecking Technology for Partial Combustion Claus
4.5 Cost of 10% Debottlenecking Using COPE Process
5 Debottlenecking Claus Split Flow System by 10% with Zinc Titanates
6 Debottlenecking Claus Sulfur Recycle System With Zinc Titanate
7 Effect of Zinc Titanate Debottlenecking on Existing Tail; Gas Treatment Systems
7.1 Selectox
7.2 SuperClaus99
7.3 Superclaus 99.5
7.4 SCOT Process
7.5 Zinc Titanate as a Claus Tail Gas Treatment
7.6 H2S Removal Efficiency With Zinc Titanate
8 Effects on COS and CS2 Formation
9 Questions for further Investigation
FIGURES
Figure 1 Claus Unit and TGCU
Figure 2 Claus Process
Figure 3 Typical Claus Sulfur Recovery Unit
Figure 4 Two-Stage Claus SRU
Figure 5 The Super Claus Process
Figure 6 SCOT
Figure 7 SCOT/BSR-MDEA (or clone) TGCU
REFERENCES: PATENTS
US4333855_PROMOTED_ZINC_TITANATE_CATALYTIC_AGENT
US4394297_ZINC_TITANATE_CATALYST
US6338794B1_DESULFURIZATION_ZINC_TITANATE_SORBENTS
SYNGAS CONDITIONING UNIT FEASIBILITY CASE STUDY: COAL-TO-LIQUIDSGerard B. Hawkins
SYNGAS CONDITIONING UNIT FEASIBILITY CASE STUDY: COAL-TO-LIQUIDS
Case Study: #0953616GB/H
HT SHIFT REACTOR CATALYST SPECIFICATION
Process Specification
This process duty specification refers to a Syngas Conditioning Unit which utilizes HT Shift reaction technology on a slip stream of raw gas to produce a recombined gas stream with a H2:CO ratio of 1.57:1. This is an important consideration as the Shift reactor is not required to minimize CO at outlet, and this specification refers to the expected performance that can be achieved in a single stage reactor scheme.
The Syngas Conditioning Unit is part of a proposed coal-to-liquids complex in which synthesis gas is produced by gasification of coal for downstream processing in a Fischer Tropsch reactor and Hydrocracker unit.
Methanol Casale Advanced Reactor Concept (ARC) Converter Retrofit CASE STUDY #10231406
For older methanol plants, efficiency is worse than for a modern plant
• To maximize profit we must improve either
– Plant efficiency
– Plant production rate
This case study highlights the revamp of a Middle Eastern Methanol Plant ARC converter with part IMC internals, to improve efficiency and production; with no CO2 addition to the Synloop, and with CO2 addition to the Synloop.
- 250 TPD CO2
- 500 TPD CO2
Changing Best Practices in Flue Gas AnalysisYokogawa1
Zirconium Oxide and Catalytic Bead sensor based analyzers have been the primary means of flue gas analysis for control and safety. The recently published API-556 has highlighted several considerations when using these technologies that were not commonly known throughout the industry. This webinar will explain the theory of operation of tunable diode laser spectrometers and the application thereof to gas fired reformers, boilers, & heaters as a layer of protection during startup and efficiency diagnostic during operation.
During this webinar recording, you will learn:
-What is the purpose of flue gas?
-The evolution of flue gas Analyzers
-Industry standards and recommended practices on the application of different types of instruments
Future carbon capture R&D efforts need to focus on cost reductions in three main areas: materials, processes and equipment. In this webinar Ron Munson, the Institute’s Principal Manager – Capture, gave an overview of the current directions in carbon capture R&D, including development of higher performance solvents, sorbents and membranes; process improvements and intensification; equipment development; and novel equipment designs.
The presentation discusses the various factors which affect the performance of Power Boilers including the quality of coal, airheater performance, air ingress etc.
Getting the Most Out of Your Refinery Hydrogen PlantGerard B. Hawkins
Getting the Most Out of Your Refinery Hydrogen Plant
Contents
Summary
1 Introduction
2 "On-purpose" Hydrogen Production
3 Operational Aspects
4 Uprating Options on the Steam Reformer
4.1 Steam Reforming Catalysts and Tube Metallurgy
4.2 Oxygen-blown Secondary Reformer
4.3 Pre-reforming
4.4 Post-reforming
5 Downstream Units
6 Summary of Uprating Options
7 Conclusions
GE / Texaco Gasifier Feed to a Lurgi Methanol Plant and its Effect on Methano...Gerard B. Hawkins
GE / Texaco Gasifier Feed to a Lurgi Methanol Plant and its Effect on Methanol Production
CONTENTS
0 Methanol Synthesis Introduction
1 Executive Summary
2 Design Basis
2.1.1 Train I Design Basis
2.1.2 Train II Design Basis
2.1.3 Train III Design Basis
2.2 Design Philosophy
2.2.1 Operability Review
2.3 Assumptions
2.4 Train IV Flowsheet
2.4.1 CO2 Removal
3 Discussion
3.1 Natural Gas Consumption Figures
3.1.1 Base Case
3.1.2 Case 1 – Coal Gasification in Service
3.1.3 Case 2 – Coal Gasification in Service – No CO2 Export
3.2 Methanol Production Figures
3.2.1 Base Case
3.2.2 Case 1 – Coal Gasification in Service
3.2.3 Case 2 – Coal Gasification in Service – No CO2 Export
3.3 85% Natural Gas Availability
3.4 100% Natural Gas Availability
3.5 CO2 Emissions
3.5.1 Base Case
3.5.2 Case 1 – Coal Gasification in Service
3.5.3 Case 2 – Coal Gasification in Service – No CO2 Export
3.6 Specific Consumption Figures
3.6.1 Base Case
3.6.2 Case 1 – Coal Gasification and CO2 Import
3.6.3 Case 2 – Coal Gasification and No CO2 Import
3.7 Train IV Synthesis Gas Composition
4 Further Work
5 Conclusion
APPENDIX
Important Stream Data – Material Balance Stream Data
Texaco Gasifier with HP Steam Raising Boiler
CHARACTERISTICS OF COAL
Material Balance Considerations
Please join GEO Inc. for a technical presentation on C3™ Technology (Cooling, Compression, Condensation) that will provide regulators, consultants, and field applicators with an understanding of the appropriate and diverse uses of this advanced vapor extraction and treatment system. Additionally, this slideshow will help identify when C3 Technology should be used, and how to apply the technology most effectively to achieve optimal efficiency and output rates.
The Art of the Pitch: WordPress Relationships and SalesLaura Byrne
Clients don’t know what they don’t know. What web solutions are right for them? How does WordPress come into the picture? How do you make sure you understand scope and timeline? What do you do if sometime changes?
All these questions and more will be explored as we talk about matching clients’ needs with what your agency offers without pulling teeth or pulling your hair out. Practical tips, and strategies for successful relationship building that leads to closing the deal.
Builder.ai Founder Sachin Dev Duggal's Strategic Approach to Create an Innova...Ramesh Iyer
In today's fast-changing business world, Companies that adapt and embrace new ideas often need help to keep up with the competition. However, fostering a culture of innovation takes much work. It takes vision, leadership and willingness to take risks in the right proportion. Sachin Dev Duggal, co-founder of Builder.ai, has perfected the art of this balance, creating a company culture where creativity and growth are nurtured at each stage.
Kubernetes & AI - Beauty and the Beast !?! @KCD Istanbul 2024Tobias Schneck
As AI technology is pushing into IT I was wondering myself, as an “infrastructure container kubernetes guy”, how get this fancy AI technology get managed from an infrastructure operational view? Is it possible to apply our lovely cloud native principals as well? What benefit’s both technologies could bring to each other?
Let me take this questions and provide you a short journey through existing deployment models and use cases for AI software. On practical examples, we discuss what cloud/on-premise strategy we may need for applying it to our own infrastructure to get it to work from an enterprise perspective. I want to give an overview about infrastructure requirements and technologies, what could be beneficial or limiting your AI use cases in an enterprise environment. An interactive Demo will give you some insides, what approaches I got already working for real.
Essentials of Automations: Optimizing FME Workflows with ParametersSafe Software
Are you looking to streamline your workflows and boost your projects’ efficiency? Do you find yourself searching for ways to add flexibility and control over your FME workflows? If so, you’re in the right place.
Join us for an insightful dive into the world of FME parameters, a critical element in optimizing workflow efficiency. This webinar marks the beginning of our three-part “Essentials of Automation” series. This first webinar is designed to equip you with the knowledge and skills to utilize parameters effectively: enhancing the flexibility, maintainability, and user control of your FME projects.
Here’s what you’ll gain:
- Essentials of FME Parameters: Understand the pivotal role of parameters, including Reader/Writer, Transformer, User, and FME Flow categories. Discover how they are the key to unlocking automation and optimization within your workflows.
- Practical Applications in FME Form: Delve into key user parameter types including choice, connections, and file URLs. Allow users to control how a workflow runs, making your workflows more reusable. Learn to import values and deliver the best user experience for your workflows while enhancing accuracy.
- Optimization Strategies in FME Flow: Explore the creation and strategic deployment of parameters in FME Flow, including the use of deployment and geometry parameters, to maximize workflow efficiency.
- Pro Tips for Success: Gain insights on parameterizing connections and leveraging new features like Conditional Visibility for clarity and simplicity.
We’ll wrap up with a glimpse into future webinars, followed by a Q&A session to address your specific questions surrounding this topic.
Don’t miss this opportunity to elevate your FME expertise and drive your projects to new heights of efficiency.
Software Delivery At the Speed of AI: Inflectra Invests In AI-Powered QualityInflectra
In this insightful webinar, Inflectra explores how artificial intelligence (AI) is transforming software development and testing. Discover how AI-powered tools are revolutionizing every stage of the software development lifecycle (SDLC), from design and prototyping to testing, deployment, and monitoring.
Learn about:
• The Future of Testing: How AI is shifting testing towards verification, analysis, and higher-level skills, while reducing repetitive tasks.
• Test Automation: How AI-powered test case generation, optimization, and self-healing tests are making testing more efficient and effective.
• Visual Testing: Explore the emerging capabilities of AI in visual testing and how it's set to revolutionize UI verification.
• Inflectra's AI Solutions: See demonstrations of Inflectra's cutting-edge AI tools like the ChatGPT plugin and Azure Open AI platform, designed to streamline your testing process.
Whether you're a developer, tester, or QA professional, this webinar will give you valuable insights into how AI is shaping the future of software delivery.
UiPath Test Automation using UiPath Test Suite series, part 4DianaGray10
Welcome to UiPath Test Automation using UiPath Test Suite series part 4. In this session, we will cover Test Manager overview along with SAP heatmap.
The UiPath Test Manager overview with SAP heatmap webinar offers a concise yet comprehensive exploration of the role of a Test Manager within SAP environments, coupled with the utilization of heatmaps for effective testing strategies.
Participants will gain insights into the responsibilities, challenges, and best practices associated with test management in SAP projects. Additionally, the webinar delves into the significance of heatmaps as a visual aid for identifying testing priorities, areas of risk, and resource allocation within SAP landscapes. Through this session, attendees can expect to enhance their understanding of test management principles while learning practical approaches to optimize testing processes in SAP environments using heatmap visualization techniques
What will you get from this session?
1. Insights into SAP testing best practices
2. Heatmap utilization for testing
3. Optimization of testing processes
4. Demo
Topics covered:
Execution from the test manager
Orchestrator execution result
Defect reporting
SAP heatmap example with demo
Speaker:
Deepak Rai, Automation Practice Lead, Boundaryless Group and UiPath MVP
DevOps and Testing slides at DASA ConnectKari Kakkonen
My and Rik Marselis slides at 30.5.2024 DASA Connect conference. We discuss about what is testing, then what is agile testing and finally what is Testing in DevOps. Finally we had lovely workshop with the participants trying to find out different ways to think about quality and testing in different parts of the DevOps infinity loop.
Neuro-symbolic is not enough, we need neuro-*semantic*Frank van Harmelen
Neuro-symbolic (NeSy) AI is on the rise. However, simply machine learning on just any symbolic structure is not sufficient to really harvest the gains of NeSy. These will only be gained when the symbolic structures have an actual semantics. I give an operational definition of semantics as “predictable inference”.
All of this illustrated with link prediction over knowledge graphs, but the argument is general.
LF Energy Webinar: Electrical Grid Modelling and Simulation Through PowSyBl -...DanBrown980551
Do you want to learn how to model and simulate an electrical network from scratch in under an hour?
Then welcome to this PowSyBl workshop, hosted by Rte, the French Transmission System Operator (TSO)!
During the webinar, you will discover the PowSyBl ecosystem as well as handle and study an electrical network through an interactive Python notebook.
PowSyBl is an open source project hosted by LF Energy, which offers a comprehensive set of features for electrical grid modelling and simulation. Among other advanced features, PowSyBl provides:
- A fully editable and extendable library for grid component modelling;
- Visualization tools to display your network;
- Grid simulation tools, such as power flows, security analyses (with or without remedial actions) and sensitivity analyses;
The framework is mostly written in Java, with a Python binding so that Python developers can access PowSyBl functionalities as well.
What you will learn during the webinar:
- For beginners: discover PowSyBl's functionalities through a quick general presentation and the notebook, without needing any expert coding skills;
- For advanced developers: master the skills to efficiently apply PowSyBl functionalities to your real-world scenarios.
Search and Society: Reimagining Information Access for Radical FuturesBhaskar Mitra
The field of Information retrieval (IR) is currently undergoing a transformative shift, at least partly due to the emerging applications of generative AI to information access. In this talk, we will deliberate on the sociotechnical implications of generative AI for information access. We will argue that there is both a critical necessity and an exciting opportunity for the IR community to re-center our research agendas on societal needs while dismantling the artificial separation between the work on fairness, accountability, transparency, and ethics in IR and the rest of IR research. Instead of adopting a reactionary strategy of trying to mitigate potential social harms from emerging technologies, the community should aim to proactively set the research agenda for the kinds of systems we should build inspired by diverse explicitly stated sociotechnical imaginaries. The sociotechnical imaginaries that underpin the design and development of information access technologies needs to be explicitly articulated, and we need to develop theories of change in context of these diverse perspectives. Our guiding future imaginaries must be informed by other academic fields, such as democratic theory and critical theory, and should be co-developed with social science scholars, legal scholars, civil rights and social justice activists, and artists, among others.
Slack (or Teams) Automation for Bonterra Impact Management (fka Social Soluti...Jeffrey Haguewood
Sidekick Solutions uses Bonterra Impact Management (fka Social Solutions Apricot) and automation solutions to integrate data for business workflows.
We believe integration and automation are essential to user experience and the promise of efficient work through technology. Automation is the critical ingredient to realizing that full vision. We develop integration products and services for Bonterra Case Management software to support the deployment of automations for a variety of use cases.
This video focuses on the notifications, alerts, and approval requests using Slack for Bonterra Impact Management. The solutions covered in this webinar can also be deployed for Microsoft Teams.
Interested in deploying notification automations for Bonterra Impact Management? Contact us at sales@sidekicksolutionsllc.com to discuss next steps.
Epistemic Interaction - tuning interfaces to provide information for AI supportAlan Dix
Paper presented at SYNERGY workshop at AVI 2024, Genoa, Italy. 3rd June 2024
https://alandix.com/academic/papers/synergy2024-epistemic/
As machine learning integrates deeper into human-computer interactions, the concept of epistemic interaction emerges, aiming to refine these interactions to enhance system adaptability. This approach encourages minor, intentional adjustments in user behaviour to enrich the data available for system learning. This paper introduces epistemic interaction within the context of human-system communication, illustrating how deliberate interaction design can improve system understanding and adaptation. Through concrete examples, we demonstrate the potential of epistemic interaction to significantly advance human-computer interaction by leveraging intuitive human communication strategies to inform system design and functionality, offering a novel pathway for enriching user-system engagements.
"Impact of front-end architecture on development cost", Viktor TurskyiFwdays
I have heard many times that architecture is not important for the front-end. Also, many times I have seen how developers implement features on the front-end just following the standard rules for a framework and think that this is enough to successfully launch the project, and then the project fails. How to prevent this and what approach to choose? I have launched dozens of complex projects and during the talk we will analyze which approaches have worked for me and which have not.
1. Criteria for Maximising Output and AFR with Relevant
OH&S Requirements
- Tom Lowes
- John Jones -
2.
3. Cement Production Scenario
In Asia whilst it generally has not suffered as much as the Western World in
terms of downturn and in many areas the market is sold out and production is
still king, the use of Alternative Fuels and Raw Materials (AFR) by the Cement
Industry is becoming an increasingly important part of a Countries Strategy to
resolve it’s recycling and waste production issues.
The Customers Produce Waste, the Pre- Processing entity converts the Waste
to AFR which is then used for Co Processing
The Co Processing of AFR by the Cement Industry has potential bottom line
benefits to its highest cost item, that of Fuel Costs, however there can be
significant issues associated with the use of AFR associated with:-
loss of output
appropriate pre and co-processing and increased OH&S requirements
increased emissions
Even when the market is not sold out, the Plant needs to perform near to
maximum output when it is producing, due to needs of operational efficiency.
When the market is sold out, any loss in output can make a big difference to
the Plant profit.
This paper outlines how to maximise output and minimise emission increase
while using AFR together with the OH&S requirements to achieve it
5. The loss in output can be significant unless the AFR to be used is well
understood in relation to the Plants operational bottlenecks plus impact on
emissions and clinker quality, which results in significantly less being used
than planned or contracted and a poor return on the investment in pre and
co-processing systems.
While the use of AFR generally leads to a drop in NOx, its higher volatility,
variability and size compared to prime fuels, can lead to increased CO and
VOCs and SO3 cycles, leading to emission regulation problems and build up
issues leading to Plant stoppages.
CINAR have the Process Knowledge of the Plant issues associated with the
co-processing of AFR and via its Multi Fuel, Minerals Interactive – CFD,
(which has been customized for the Cement Industry) can resolve any output
or emission issue either at the operational or planning stage.
Our unique MI CFD allows one to go inside the kiln or calciner, have a look
around, find how it is working and try some solutions before implementing it
on a large scale.
However the best analytical tools in the world do not help much unless the
basics of the process are well understood and the pre and co-processing
systems as well as the OH&S are not done well.
Using AFR
6. Needs
Avoid excessive build up
No Significant loss of output
No increased VOC emission
Hit NOx targets
Rules for AFR and Petcoke
VFSO3 < 2
HM Carbon < 0.1%
HM Cl < 1% - 1% by pass per 100mg/kgClk > 300
Eliminate Kiln and Calciner Stratification
Need Tom not 3Ts
M – Temperature
O – Oxygen
T – Micro-mixing
Additional for 500 mg/Nm3
Tom ++
i.e. Volatiles and sub stoichiometric RT
Using AFR Effectively
Combustion in a
very narrow
region
SIGNIFICANT
STRATIFICATION
and waste of
space and hence
need big RT
7. Impact of AFR on Output
There is much myth and folklore surrounding AFR and its impact on
output, let alone emissions and clinker quality.
The output losses are always related to current maximum performance in
sold out market – even if it is not – and hence this is normally a fan
limitation. Hence anything that increases the gas volume, due to H2O,
increased fuel consumption or O2 needs can be seen as a drop in output.
The first major rule to apply is seeking to minimise the impact of AFR on
output is:- %TSR (Thermal Substitution Rate) * Short Terms Thermal
Input Fluctuations = <100%
For example, if the Plant is at 50% TSR the STTIF (one minute) has to be
<2%. If it was for example 7%, up an extra 1.0 % O2 could be needed to
avoid CO and hence potential 6% loss in output.
So to go to the higher AFR rates: good pre-processing, handling, firing
systems are needed, plus of course excellent process knowledge.
The next issues are the impact of H2O, ash, exit temperature and extra O2
have on output. The table on the next shows for a PH/Calciner, where GC-
Giga Cals t-tonnes and fc – fuel consumption.
8. Impact of AFR on Output
The simple one to assess is that impact of H2O and Ash on output with
water being by far the higher. For example a 4000 tpd plant with 50%
of its fuel with 30% water will lose @140 tpd of output or 3.5%.
Poor AFR control needing an extra 1% O2 will lose 6% output.
Poor riser or calciner firing will increase the PH exit temperature by
100C increasing fuel consumption by 50 kcals/kg and losing 2.5% in
output – A CURRENT MI-CFD PROJECT.
The O2 and increased PH temperature can be negated via good process
engineering aided by MI-CFD, however the impact of ash and H2O is
down to the availability of the AFR and various choices as to
preparation, specification and price.
9. Impact of AFR on Output
In addition, with AFR there are many process problems associated with a
longer flame, reducing conditions in the kiln and hot meal due to unburnts
in the hot meal driving the SO3 cycles and build up. They are a function of
the process and the fuels used as well as the level of external help given to
supplement the local process knowledge.
It is imperative for successful AFR use at a Plant that the choice of AFR
quality is made with reference to the Plant co processing and pyro
capabilities.
However to get your Pyro Plant AFR one first has to know your Plants Pyro
State and Eliminate Stratification to avoid significant loss is output and
increased VOC/CO emissions.
While the Calciner performance dominates the AFR TSR potential, the role
of a poor/ good burner cannot be overlooked.
10. Good Kiln Burner Criteria to Avoid Stratification
Kiln Burners Rules forn 75% TSR
11N/ MW
CO < 200 ppm at
1.2% O2
NOx max to 2.5% O2
VF SO3 < 3
Avoid cooler/ kiln
hood SA flow
distortion
These will allow
unburnt C in hot meal
burnout before the
after calcination zone
and 75% Burner TSR
11. 100 % Calciner TSR
Impossible many would say without 8 secs RT, many Asian calciners are < 3
secs, so is 100% TSR impossible?
NO!!! CINAR has modified a 2 sec RT for £1.5m that can get 100% TSR
Look at the car development
1 litre engines now produce the power of 10 litres 50 years ago
How has the development been done?
Via well customised CFD programmes for Engine combustion for both
diesel and gasoline
A customised CFD programme – MI-CFD – can do the same for a small
calciner
SO Tune the Engine, give it a TOM
What is the Engine
Coal and AFR injection, TA , meal and gas riser.
The micro mixing or O2 and fuels need to be optimised with respect to
combustion and heat transfer to the meal.
The is little point in adding volume at the cold end if the engine is
poorly tuned.
12. 100 % Calciner TSR
CINAR did initially work for this calciner plant to overcome problems of poor coal
burnout and calcination and very bad build up.
This is shown on the next 3 slides, how a low cost modification to the TA inlets
enabled them to overcome the problem and get to @ 70% calciner TSR with an
Engineered Fuel (SRF), however the Plant Manager wanted to get to 100%.
As the calciner has only 2 secs RT this proved to be difficult for them, due to CO,
less of output and elevated PH outlet temperature and we were asked again to
help.
From simulations of the current operations it was identified that:-
The SRF was being quenched too fast to get a good burnout and its path was going
to the lower O2 regions in the calciner and only burning out to 73%.
Simulations of the SRF and coal injection points, plus meal splits and a venturi, a
series of recommendations were made to get potential to 100% TSR.
13. Oxygen Mass Fraction [-]
Original 2
TA inlets,
very poor
mixing with
the coal
Modified
TA to a
Horseshoe
Original Modified
Burnout % 70 93
Calcination % 70 90
14. Oxygen Profiles/ Fuel Trajectories
Coal / O2
O2 [m/ m]
EF / O2
The EF releases
if volatiles
fast, but is then
quenched too
fast by the meal
and then travels
in a low O2
region which
makes the
burnout poor
Near the walls of
there are oxygen
rich areas where
available oxygen
would enhance
the burnout
Case Base Case
Coal Burnout (%) 99
EF Burnout % 73
Total Burnout % 81
Calcination 95
70% TSR increased
CO and kcals/kg and
lower output
15. EF particles in O2 - Meal particles in Temperature
70%
Profuel Axial Sleeve of
EF injectors
100%
Profuel
O2
T (C)
Adding a
lower meal
inlet
Currently
being
implemented
16. Implementation and Feedback
Based on the MI-CFD simulations, modifications were proposed to the SRF
burners, meal split and the installation of the customized venturi design
not only to stop the SRF drop out but to improve the mixing of the O2 with
the EF. The predicted change is below:
So the burners have been modified and part of the Venturi has been
installed, with the change below from the Plant info, which shows already
85% TSR , more output, less CO and better kcals/kg, with a potential
savings of > €1mpa and a pay back on the MI-CFD of 2weeks.
•
Case 70/30 100%
Coal Burnout (%) 99 -
Eng. Fuel Burnout % 73 84
Calcination % 95 97
Exit O2 % 4.2 3.9
Calciner Exit Temperature (C) 865 866
Year Before part Mod After part Mod Percentage
Clinker tpd 2788 2838 2%
EF firing rate tph 6.8 8.2 21%
PH Exit Temperature 431 416 4%
ID fan O2 ppm 7.5 6.6 14%
ID Fan CO ppm 1110 930 19%
Fuel Comsumption kcals/kg 936 896 5%
17. Calciner Modification for AFR and Output
Options
Zero Capex – Process evaluation MI-CFD – calciner burner, AFR injection
and meal location optimised – 100 % TSR possible with specific AFR for
RTs < 3 secs
Low Capex - < $2m US – as above but with TA optimised 100% TSR possible
for a wider range of AFRs
Modest CAPEX < $5m US – SCC recent PMTech/ CINAR develop for most
AFRs up to 75mms and 100% TSR
GIVES @ 6 secs AFR RT with a gas RT volume of 1 sec RT
and fits with the new BMH TSS Concept
18. Generic Calciner for 100% TSR and Low NOx
CINAR customised HOT REBURN
– 0.15 secs at 1300C
SR volatile < 0.9
Non coating refractory (SiC)
plus blasters
Customised Venturi for AFR
Further reburn and stating
section to allow HCN -> N2
with up to 50% meal quench,
at least 0.5 secs
Opposed TA inlets
or horseshoe to
enhance mixing
and avoid
stratifications
Enhanced mixing
and combustion
region – hot spot –
controlled by rest
of meal
2.5 secs RT above TA, for
calcination and burnout
AFR and Coal
burners design
and location
customised as a
function of
specification
20. SRF Residence Time (sec.) Fn Size
Av. RT: 2 s
5 mm 10mm 20mm 30mm 50 mm
Av. RT: 4 s
Av. RT: 5 s
Av. RT: 10 s
Av. RT: 12 s
21. SRF Burnout (%)
Burnout %
Average SRF BO at
SCC exit: 96%
The bigger the SRF the
longer the RT and hence a
good Burnout is assured,
even with only a gas RT of
@ 1sec
The SCC fits nicely with the
BMH TSS concept
The SCC BURNS ALL
and the
TYRANNOSAURUS EATS
ALL
22. Calciner
optimisation
LOI compared to
Temperature
CO < 500 ppm at 2.5%
O2
PH Temperature 350 - 4
stage, 325 – stage, 290 –
6 stage
MI-CFD - O2
stratification
Burners
Meal
TA
SCC
Calciner Rules for 100% TSR
23. All well and good, but major issues are
associated with waste/ AFR platforms and
OH&S before even using AFR at a Kiln.